jcb 16c-1, Service Manual

Page 1: ...first studying the Operator s Manual You must understand and follow the instructions in the Operator s Manual If you do not understand anything ask your employer or JCB dealer to explain it Do not operate the machine without an Operator s Manual or if there is anything on the machine you do not understand Treat the Operator s Manual as part of the machine Keep it clean and in good condition Replac...

Page 2: ...9813 7900 2 Notes Find manuals at https best manuals com ...

Page 3: ...1 19C 1 PC EN 9813 7900 SERVICE MANUAL Volume 2 15C 1 16C 1 18Z 1 19C 1 19C 1 PC EN 9813 7900 SERVICE MANUAL Volume 3 15C 1 16C 1 18Z 1 19C 1 19C 1 PC EN 9813 7900 SERVICE MANUAL Volume 4 15C 1 16C 1 18Z 1 19C 1 19C 1 PC EN 9813 7900 Find manuals at https best manuals com ...

Page 4: ...Notes 9813 7900 2 Find manuals at https best manuals com ...

Page 5: ...ntenance Safety 01 7 01 03 18 Operating Safety 01 9 01 03 21 Worksite Safety 01 11 01 03 24 Risk Assessment 01 12 01 03 27 Maintenance Positions 01 13 01 06 About this Manual 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18 01 09 Description 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22 01 33 Cleaning 01 33 00 General 01 25 Find manuals at htt...

Page 6: ...9813 7900 2 2018 02 14 Acronyms Glossary PIL Parts Identification List Find manuals at https best manuals com ...

Page 7: ... 03 03 Safety Yours and Others 01 4 01 03 06 Safety Warnings 01 5 01 03 09 General Safety 01 6 01 03 12 Maintenance Safety 01 7 01 03 18 Operating Safety 01 9 01 03 21 Worksite Safety 01 11 01 03 24 Risk Assessment 01 12 01 03 27 Maintenance Positions 01 13 Find manuals at https best manuals com ...

Page 8: ...Notes 01 2 9813 7900 2 01 2 Find manuals at https best manuals com ...

Page 9: ...cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere Sparks in such an area could cause an explosion or fire resulting in death or serious injury Switch off and do not use your mob...

Page 10: ...tial hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them Do not work with the machine until you are sure that you can control it Do not st...

Page 11: ...NG indicates a hazardous situation which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word Notice indicates a hazardous situation which if not avoided could result in machine damage The safety alert system symbol shown also helps to identify important safety me...

Page 12: ...re of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere Sparks in such an area could cause an explosion or fire resulting in death or serious injury Switch o...

Page 13: ...ulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure the hose service line has been vented before connecting or removing hoses Make sure the engine cannot be started while the hoses are open O rings Seals and Gaskets Badly installed damaged or rotted O r...

Page 14: ...ecomposition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater than 300 C 571 6 F e g engine fire must be treated using the following safety procedure Make sure that heavy duty gloves and special safety glasses are worn Thoroughly wash contaminated area with 10 cal...

Page 15: ...ly kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel drowsy stop the machine at once and get into fresh air Worksites Worksites can be hazardous Examine the site before working on it You could be killed or injured if the ground gives way under your machin...

Page 16: ... see clearly Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When using the machine keep your hands and feet clear of moving parts Keep your hands and feet within the operator compartment while the vehicle is in motion Contro...

Page 17: ... leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be running You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes CAUTION Before you start using the mach...

Page 18: ...and is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it will be by wind speeds Is it an awkward shape How is the weight distributed Uneven loads are more difficult to handle Is there a possibility of the load shifting while being moved Loading Unloading Are...

Page 19: ... on solid level ground 1 1 Push the hand throttle lever to the idle position 2 Lower the dozer to the ground 3 Lower the excavator so the attachment is flat on the ground Figure 2 4 Stop the engine 5 Discharge the hydraulic pressure Refer to PIL 30 00 00 6 Isolate the controls 7 Disconnect the battery to prevent accidental operation of the engine Refer to PIL 33 03 00 ...

Page 20: ...d on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery by means of the battery isolator if installed when you are not using electrical power If you do not take these precautions you could be killed or injured WARNING Make the machine safe before getting beneath it Make sure that any attachments on the machine are correctly attached Engage the p...

Page 21: ...01 Machine 06 About this Manual 01 15 9813 7900 2 01 15 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18 ...

Page 22: ...Notes 01 16 9813 7900 2 01 16 ...

Page 23: ...l and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 2700721 2701320 15C 1 2709461 2710460 16C 1 2701321 2702320 2493516 2493975 18Z 1 2493516 2493975 2492571 2493515 19C 1 2492571 2493515 19C 1 PC 2493976 2494335 ...

Page 24: ...h information is for which variant Make sure you use the correct information Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the following Make sure that the operator understands the machine controls functions and use Refer to the applicable Operator Manual Check that the maintenance record complies with the applicable...

Page 25: ...01 Machine 09 Description 01 19 9813 7900 2 01 19 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22 ...

Page 26: ...Notes 01 20 9813 7900 2 01 20 ...

Page 27: ...01 21 9813 7900 2 01 21 12 Main Component Locations Introduction Figure 4 A C G E F D B A Cab canopy contains the operator station B Boom part of the excavator arm C Dipper part of the excavator arm D Bucket E Dozer blade F Undercarriage G Upper structure ...

Page 28: ...ion The following illustrations identify the service points for the operator to perform the daily and weekly maintenance tasks Engine Compartment Figure 5 C H A B D E G F A Air filter B Water separator C Oil filler cap D Coolant expansion bottle E Battery F Engine oil dipstick G Battery isolator H Fuel pre filter ...

Page 29: ...Machine 09 Description 15 Service Point Locations 01 23 9813 7900 2 01 23 Hydraulic Compartment Figure 6 C B A D A Radiator cap B Hydraulic tank filler cap C Fuel filler cap D Hydraulic oil level indicator ...

Page 30: ...01 Machine 33 Cleaning 01 24 9813 7900 2 01 24 33 Cleaning Contents Page No 01 33 00 General 01 25 ...

Page 31: ...render the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures that require components to be removed The cleaning must be done either in the area of components to be removed or in the case of major work or work on the fuel system the whole engine and the surroun...

Page 32: ...t aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oil The product must always be greased if appropriate after pressure washing or steam cleaning Preparation 1 Make the machine safe Stop the machine and let it cool for at least one hour Do not try to c...

Page 33: ... and Load Handling Contents Page No Acronyms Glossary 03 2 03 00 Attachments 03 00 00 General 03 3 03 10 Excavator End Quickhitch 03 10 00 General 03 7 03 27 Bucket 03 27 00 General 03 17 03 27 90 Teeth 03 20 03 48 Rockbreaker 03 48 00 General 03 25 ...

Page 34: ...9813 7900 2 2018 02 19 Acronyms Glossary LED Light Emitting Diode ...

Page 35: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 7900 2 03 1 00 Attachments Contents Page No 03 00 00 General 03 3 ...

Page 36: ...Notes 03 2 9813 7900 2 03 2 ...

Page 37: ...ty the gradients on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactured specifically to suit the machine s hydraulic system mounting arrangements and safe load requirements Attachments which are not designed for use with this machine may cause damage and cr...

Page 38: ...oad and unload on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the attachments to the ground make sure that the machine and the area around it are clear of other people Anyone on or close to the machine could fall and be crushed by the attachments or get caught in the linkages DANGER Using the forks alone as a working pla...

Page 39: ...03 Attachments Couplings and Load Handling 10 Excavator End Quickhitch 03 5 9813 7900 2 03 5 10 Excavator End Quickhitch Contents Page No 03 10 00 General 03 7 ...

Page 40: ...Notes 03 6 9813 7900 2 03 6 ...

Page 41: ...ches are used on machines to allow the rapid change of buckets and attachments on the machine Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations but when installed on a machine they become a part of the overall machine system They are usually mounted on the machine by means of pins that would otherwise be the mountings for ...

Page 42: ...ilure could result in the sudden release of an attachment from the machine and you or others could be killed or seriously injured WARNING The attachment will move when released Stand clear and to one side when releasing the attachment WARNING Attachments that are installed with the use of loader or excavator quickhitches must not be used to transport or lift persons if the machine is not designed ...

Page 43: ...ade for the weight of the quickhitch on the rated operating load The mass of the Quickhitch is stamped on the data plate The excavator Quickhitch which is attached to the dipper enables fast removal and installation of the bucket and other attachments There are two types of Quickhitch available manual and hydraulic Compatibility of the Quickhitch must be checked with Quickhitch manufacturer For th...

Page 44: ...running 4 Enable the hydraulic controls 5 Press the Quickhitch switch on the switch console The light on the control isolation switch will start flashing on the switch panel 6 With the Quickhitch unlocked LED Light Emitting Diode flashing buzzer sound and instrument panel displaying Quickhitch unlocked symbol position the Quick hitch on top of the attachment you want to engage 7 Press the Quickhit...

Page 45: ...ked symbol will display on the instrument panel At this point operator can cancel the procedure by pressing the Quickhitch switch or deactivating the hydraulics or turning the ignition off and Quickhitch will be locked Figure 8 9 For deactivating the hydraulic Engage Manual 1 Set the attachment on solid level ground Use safe and correct lifting equipment to move the attachment 2 Position the machi...

Page 46: ... the attachment could fall and you could be killed or injured 6 Make sure that the pivot pin has fully engaged into the latch Disengage Manual 1 Park the machine on solid level ground 2 Position the attachment just clear of the ground and at an angle such that it does not detach from the front pivot pin when the Quickhitch is unlatched 3 Stop the engine and disconnect the attachment hydraulic hose...

Page 47: ...ng the attachment 5 Apply a downward pressure on the bar to release the attachment rear pivot pin from the latch hook allowing it to swing forward as shown Figure 12 A A Pivot pin 6 Remove the tommy bar from the Quickhitch 7 Start the engine and carefully rest the attachment on the ground 8 Slowly roll the Quickhitch back in the direction of arrow and simultaneously raise the dipper arm to release...

Page 48: ...03 Attachments Couplings and Load Handling 10 Excavator End Quickhitch 00 General 03 14 9813 7900 2 03 14 Figure 13 A B A Pivot pin B Jaw ...

Page 49: ...03 Attachments Couplings and Load Handling 27 Bucket 03 15 9813 7900 2 03 15 27 Bucket Contents Page No 03 27 00 General 03 17 03 27 90 Teeth 03 20 ...

Page 50: ...Notes 03 16 9813 7900 2 03 16 ...

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